Effects of Key 3D concrete printing process parameters on layer shape: Experimental study and Smooth Particle Hydrodynamics modelling

An, D; Rahman, M; Zhang, YX; Yang, R

Effects of Key 3D concrete printing process parameters on layer shape: Experimental study and Smooth Particle Hydrodynamics modelling

An, D Rahman, M Zhang, YX Yang, R

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Publisher:: Elsevier
Publication Type:: Journal Article
Citation:: Case Studies in Construction Materials, 2025, 22, pp. e04718
Issue Date:: 2025-07

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Field	Value	Language
dc.contributor.author	An, D
dc.contributor.author	Rahman, M
dc.contributor.author	Zhang, YX
dc.contributor.author	Yang, R
dc.date.accessioned	2025-12-18T02:44:03Z
dc.date.available	2025-12-18T02:44:03Z
dc.date.issued	2025-07
dc.identifier.citation	Case Studies in Construction Materials, 2025, 22, pp. e04718
dc.identifier.issn	2214-5095
dc.identifier.uri	http://hdl.handle.net/10453/190974
dc.description.abstract	3D concrete printing (3DCP) is an innovative technology with significant potential in construction. However, it faces critical challenges in achieving precise layer geometry and dimensional accuracy, as small geometric deviations in individual layers can compromise the stability and performance of the entire structure. To investigate the underlying deformation mechanisms, this study develops an integrated analysis framework combining experimental study with Smooth Particle Hydrodynamics (SPH) modelling. Key rheological and process parameters for 3DCP are identified experimentally. For the first time, a novel three-dimensional (3-D) SPH model is devised to simulate single- and double-layer concrete printing processes, considering nozzle moving speed, material inlet speed, and nozzle height. The high consistency between experimental and SPH results demonstrates the accuracy of models in predicting layer shape and tracking inter-layer deformations. Parametric analysis reveals a self-compensatory effect of nozzle height on layer height variations and demonstrates that a lower nozzle speed to material inlet velocity ratio improves layer shape and structural performance. These findings provide insights into the control of construction materials to enhance printing quality and structural reliability in 3DCP.
dc.language	en
dc.publisher	Elsevier
dc.relation.ispartof	Case Studies in Construction Materials
dc.relation.isbasedon	10.1016/j.cscm.2025.e04718
dc.rights	info:eu-repo/semantics/openAccess
dc.subject.classification	4005 Civil engineering
dc.title	Effects of Key 3D concrete printing process parameters on layer shape: Experimental study and Smooth Particle Hydrodynamics modelling
dc.type	Journal Article
utslib.citation.volume	22
pubs.organisational-group	University of Technology Sydney
pubs.organisational-group	University of Technology Sydney/Faculty of Engineering and Information Technology
pubs.organisational-group	University of Technology Sydney/Faculty of Engineering and Information Technology/School of Mechanical and Mechatronic Engineering
pubs.organisational-group	University of Technology Sydney/UTS Groups
pubs.organisational-group	University of Technology Sydney/UTS Groups/Centre for Advanced Manufacturing (CAM)
utslib.copyright.status	open_access	*
dc.rights.license	This work is licensed under a Creative Commons Attribution 4.0 International License (CC BY 4.0). To view a copy of this license, visit https://creativecommons.org/licenses/by/4.0/
dc.date.updated	2025-12-18T02:44:02Z
pubs.publication-status	Published
pubs.volume	22

Abstract:

3D concrete printing (3DCP) is an innovative technology with significant potential in construction. However, it faces critical challenges in achieving precise layer geometry and dimensional accuracy, as small geometric deviations in individual layers can compromise the stability and performance of the entire structure. To investigate the underlying deformation mechanisms, this study develops an integrated analysis framework combining experimental study with Smooth Particle Hydrodynamics (SPH) modelling. Key rheological and process parameters for 3DCP are identified experimentally. For the first time, a novel three-dimensional (3-D) SPH model is devised to simulate single- and double-layer concrete printing processes, considering nozzle moving speed, material inlet speed, and nozzle height. The high consistency between experimental and SPH results demonstrates the accuracy of models in predicting layer shape and tracking inter-layer deformations. Parametric analysis reveals a self-compensatory effect of nozzle height on layer height variations and demonstrates that a lower nozzle speed to material inlet velocity ratio improves layer shape and structural performance. These findings provide insights into the control of construction materials to enhance printing quality and structural reliability in 3DCP.

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http://hdl.handle.net/10453/190974